Integral Casting Flow Passage Using a Smart Core to Prevent Leakage
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Solution Overview
Problem
Conventional methods for forming castings with flow passages are complex and prone to leakage, which can lead to water permeation and potential vehicle malfunctions or fires due to the mechanical coupling of two parts and the use of gaskets, necessitating a technique to enhance the robustness and reduce production costs.
Innovation Solution
A method involving a tubular pipe filled with a filler to form a smart core, which is inserted into a mold and filled with molten metal through a high-pressure casting process, allowing for the formation of a robust, integral casting with a flow passage shape, where the tubular pipe and molten metal are made of the same material, such as aluminum, and the filler has a thermal conductivity of 0.1 W/m·°C to 1 W/m·°C and a particle size of 100 μm or less.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two parts with flow passages are formed through casting processes and coupled with each other by bolts and gaskets, then the flow passage can be formed in the casting, but the production process becomes complex and leakage may occur
Solution Approach 1:
The patent merges two separate casted parts into a single integral casting by forming the flow passage directly within the casting body. This eliminates the need for mechanical coupling of two parts with bolts and gaskets, thereby simplifying the production process and preventing leakage at junctions.
Solution Approach 2:
The patent applies preliminary action by forming the flow passage during the initial casting process itself, rather than creating it through subsequent assembly of multiple parts. The flow passage is created as an integral part of the casting, preventing leakage before assembly issues can arise.
2Ease of manufacture
If two parts are coupled with bolts and gaskets to form flow passage, then the flow passage structure can be achieved, but the risk of water permeation and malfunction increases
Solution Approach 1:
The patent combines the flow passage formation with the main casting process, creating an integral structure where the flow passage is part of the single casting body. This eliminates gaskets and joints that could permit water permeation, thereby reducing malfunction risk while maintaining ease of manufacture.
Solution Approach 2:
The patent converts the potential harm of complex assembly (which introduces leakage risks) into a benefit by using a single-casting approach. The simplification of the manufacturing process simultaneously eliminates the harmful effect of potential water permeation at joints.
3Productivity
If a single casting with flow passage is formed, then production cost is reduced and robustness is enhanced, but the casting process must ensure no deformation or leakage
Solution Approach 1:
The patent merges flow passage formation with the main casting process, achieving both productivity improvement and manufacturing precision. The flow passage is created as an integral part of the single casting, ensuring structural integrity while simplifying production to one casting operation rather than multiple assembly steps.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method reduces production costs and enhances the robustness of the flow passage, preventing leakage and deformation, while ensuring the casting is formed in one piece, thereby reducing the risk of vehicle malfunctions and fires.
Implementation Method 1
a thermal conductivity of the filler may range from 0.1 W/m·° C. to 1 W/m·° C.
Implementation Method 2
injecting molten metal into the cavity through a casting process; The casting process may be performed through a high-pressure casting process.
Data Source
AI summary
A method of forming a casting with a flow passage may include filling a tubular pipe with a filler to form a smart core; inserting the smart core into a mold having a cavity corresponding to a shape of the casting to be formed; injecting a molten metal into the cavity through a casting process; and removing the filler from the smart core, wherein a hardness of the tubular pipe is 70 Hv or more.